HERCULES Series Industry's first 60A half brick DC/DC Converter 48V Input, 1.5V, 2.2V, 3.3V or 5.0V The Hercules Series are the highest performance half brick DC/DC converters in the industry with: Output Current up to 60 Amperes Parallel up to 5 units Pin Programmable Output Voltage 200 Watts @ 100° Baseplate 69 Watts/cu. inch 2.4" x 2.4" x 0.4" Accurate Current Share Synchronizable Fixed Frequency Operation Automatic OVP tracking to Voltage Trim Output OK signal UL and CSA approved Two Year Warranty Control Functions Remote Sense Output Enable Protection Features Over Temperature Protection Over Voltage Protection Over Current Protection Typical Characteristics Output Setpoint Accuracy: ±1.25% Load & Line Regulation: ±0.25% Noise & Ripple: 75 mVp–p Long Term Temperature Drift: ±0.5% Output Trim Hercules Series, Page 1 WWW.GALAXYPWR.COM Part No. 98–002 Rev. 1.1 Specifications General Specifications Operating Temperature -20°C to +100°C baseplate Storage Temperature –40°C to +100°C Relative Humidity 10% to 95% RH, Non–condensing Vibration 10–500Hz 0.75g peak Weight 130gm, maximum Material Flammability UL94V–2 Safety UL 1950, CSA C22.2 No. 950 approved1 MTBF MIL–HDBK–217 500,000 hours2 Notes: 1. Requires one fuse located in either the plus or minus side of the 48V supply; fuse rated for 7A max for all conditions. 2. 80% load; 70°C baseplate. Input Characteristics Baseplate Temperatures from 0°C to +100°C. Parameter Name Test Condition Var Input Voltage Symbol VI Requirement Min Max Unit 36 72 V Input Low Line Power On V VIon Module Power On 30 35 V Input Low Line Power Off V VIoff Module Shutdown 80 90 %VIon VI=VInom – 2.5 W 250 – µF No Load Input Power PIL Input Capacitor rated 80V min (external to the converter) Input Current 1.5V II VI = 36V, IO = 60A, VO = 1.5V – 4.0 A 2.2V II VI = 36V, IO = 60A, VO = 2.2V – 5.2 A 3.3V II VI = 36V, IO = 50A, VO = 3.3V – 5.6 A 5.0V II VI = 36V, IO = 40A, VO = 5.0V – 6.3 A VI = 48V, IO = IO max rated – 1.0 A2s 66 – % 2.2V 74 – % 3.3V 77 – % 5.0V 80 – % VI = 48V, IO = Io max rated, CI = 250µF – 2.5 Ap-p VI = 48V, VO = VOnom – 44 W IO = IOmax rated, TCase= 70°C – 44 W 3.3V – 42 W 5.0V – 42 W Inrush Transient Efficiency 1.5V VO = VO nom , IO = IO rated, VI=VInom Reflected Input Ripple Maximum Losses at 1.5V Local Sense 2.2V Hercules Series, Page 2 Pd WWW.GALAXYPWR.COM Part No. 98–002 Rev. 1.1 Specifications Output Characteristics Over the complete baseplate temperatures and input voltage ranges. Parameter Name Output Voltage (nominal) Rated Output Current Test Condition Var Symbol 1.5V 2.2V 3.3V 5.0V 1.5V 2.2V 3.3V 5.0V VOnom VOnom VOnom VOnom IO IO IO IO Initial Output Voltage Tolerance (with remote sense) Noise and Ripple Static Load and Line Regulation Long Term Temperature Drift Voltage Programming Slope 1.5V Vadj Initial Tolerance Resistance Programming Tolerance Total Remote Sense Compensation (round trip) VO = VOnom VO = VOnom VO = VOnom VO = VOnom Vadj = open, TC = +25°C VI = VInom, IO = IOrated/2 20MHzP-P bandwidth, VI=36-72V, IO = 0 amps to 100% VI=36-72V, IO = 0.2 amps to 100% VIN = 48V VO = VOnom IO = IOrated/2 2.2V Requirement Min Typ Max Vadj = 0.5V to 1.5V – – – – 0 0 0 0 -1.25 – -0.5 – _ 0.30 ± 0.014 0.44 ± 0.02 0.66 ± 0.03 1.0 ± 0.04 – 5.0V – VI = VImin, IO = IOmax rated Output Overvoltage Protection 0.5 – %V mV/mV – mV/mV – mV/mV – mV/mV ±1.25 %VOnom -8.3 %VOnom +11.7 %VOnom 100 mV -11.7 +8.3 – – 500 mV 110 127 %VO (Latching) Output Voltage Protection mVP-P ±0.25 %VOnom – 3.3V 1.5V 2.2V 3.3V 5V – Vnom – Vnom – Vnom – Vnom 60/40 A 60/40 A 50/40 A 40/30 A 1.25 %VOnom 75 – Vadj = 1.0V Radj = 500Ω Radj = 1500Ω 1.5 2.2 3.3 5.0 – – – – – Unit prog. TOVP VO = VOnom, IO = IOrated – 30 µs Response Time Note: Overvoltage Protection must function over full programming range. Also, reference for OVP Threshold must be a redundant or equivalent reference. Hercules Series, Page 3 WWW.GALAXYPWR.COM Part No. 98–002 Rev. 1.1 Specifications Output Characteristics (continued) Over the complete baseplate temperatures and input voltage ranges. Parameter Name Current Limit (nominal) Short Circuit Current Transient Response 1, 2 Test Condition Var 1.5V 2.2V 3.3V 5.0V 1.5V 2.2V 3.3V 5.0V 1.5V Symbol IOlim IOlim IOlim IOlim Istep =15A, di/dt=10A/µsec CO = 35-470µf caps Istep =28A, di/dt=28A/µsec CO = 35-470µf caps Istep =12A, di/dt=10A/µsec CO = 10-470µf caps Istep =10A, di/dt=10A/µsec CO = 5-470µf caps 3.3V 5.0V ton Rise Time (10% to 90%) Trise Turn Off Time (to 10% initial value) toff External Load Capacitance Current Sharing (Secondary Side) Synchronization Fanout Over Temperature Shutdown VO = 90% VOnom, VI = 48V VO = 0.2 to 0.4V, VI = 72V 2.2V Settling Time to ±1% Turn On Time (to 90% final value) Min Ishare IO = 5A, VI= VImin to VImax Cin = 250µf, 80V Cout = 10,000µf tantalum & 0.47µf Ceramic VI= VImin to VImax IO= IOmin to IOmax Capacitors as in Turn On Time IO = 5A, VImin to VImax Cin = 250µf, 80V Co = 330µf tantalum & 0.47µf Ceramic ESR@17,000µf = 2mΩ Vin = 48V, Vo = Vonom I = 10% Iop to Iop TBASEPLATE 61 61 46 37 – – – – – Requirement Typ Max Unit – – – – – 72 72 54 42 80/55 80/55 70/55 55/45 3 A A A A A A A A %VOnom – – 3 %VOnom – – 3 %VOnom – – 3 %VOnom – 10 – – 600 75 µs ms 10 – 20 ms – – 2.0 ms 1,500 — 18,800 ±5 µf %IOmax 1 – 5 125 units °C – (Latching) Isolation Resistance 10 MΩ (1500VDC) Input-Output Notes: 1. Transient response is for a positive or a negative current step within the range of 5% of Imax to Imax. 2. Transient response is measured with the specified number of 470µF tantalum external load capacitors with a maximum ESR of 55mΩ each. Hercules Series, Page 4 WWW.GALAXYPWR.COM Part No. 98–002 Rev. 1.1 Specifications Control Signal Characteristics Parameter Name Test Condition Requirement Min Max Unit Enable_L asserted Enable_L de-asserted Source Current (VENABLE = 0.8V) Enable_L asserted Enable_L de-asserted Source Current (RENABLE = 100Ω) OTW_L asserted, VS = 5V, RL = 50Ω OTW_L de-asserted, VS = 15V OTW_L asserted, VS = 5V, RL =5K VI = 48V, VO = rated VO, IO= Rated IOmax, Fan-off early warning time before converter shuts down due to thermal overload MODOK_L de-asserted, VS = 15V MODOK_L asserted, VS = 5V, RL = 50Ω MODOK_L asserted, VS = 5V, RL = 5K 0 4.5 – – 200K – 8 – – 500 0.8 5.5 -1.0 100 – -1.0 20 10 0.2 – V V mA Ω Ω mA mA µA V ms – 8 – 10 20 0.2 µA mA V Symbol Enable_L Function Control Voltage (Secondary Side) Enable Function Control Resistance (Secondary Side) OTW–L Overtemperature Warning VENABLE RENABLE I SINK I LEAKAGE VL TOTW-L Time delay MODOK_L I LEAKAGE ISINK VL Maximum Output Load Current (IOP) vs Number of Converters No. of Converters 1.5V & 2.2V 3.3V 5.0V 1 2 3 4 5 60A 117A 174A 231A 288A 50A 87.75A 130.5A 173.25A 216A 40A 58.5A 87.0A 115.5A 144A Thermal Characteristics (ΘCA) Air Velocity (m/s) 0.5 1.0 1.5 2.0 2.5 Hercules Series, Page 5 Thermal Resistance (Baseplate to Ambient) °C/W 0.9" Heatsink 1.4" Heatsink 3.0 1.9 1.6 1.4 1.3 2.1 1.3 1.1 1.0 0.9 WWW.GALAXYPWR.COM Part No. 98–002 Rev. 1.1 Application Notes Signal Characteristics: Per table on page 5. The trim voltage for the GPH1V5-40 and GPH1V5-60 is: Input Signals: Enable_L: This input signal is used to enable the output of the converter when activated (active Low). The signal is referenced to the output side (–Sense). Enable_L does not require an external pull-up resistor. If an external pull-up is used it should be tied to +5V. To minimize start-up problems it is recommended that Enable_L be driven from an open-drain configured FET. Voltage Adjust: The output voltage of the converter shall be adjustable as specified in the table on page 3. The voltage adjust pin sources 1 mA current. The adjustment shall be done using an external voltage source or a resistor connected between the Voltage Adjust pin and the – Sense pin. See below for output voltage adjustment application information. Current Share: When two or more converters are connected in parallel, their current share pins must be connected together to allow proper load sharing. Sync: When two or more converters from the same manufacturer are connected in parallel, their sync pins may be connected together to synchronize their operating frequencies. When two or more converters from different manufacturers are connected in parallel their sync pins must NOT be connected together. Output Signals: MODOK_L: MODOK_L shall be asserted to indicate that the output voltage is in regulation. When two or more converters are operating in parallel a failed converter may or may not de-assert its MODOK_L signal. OTW_L: OTW_L shall be asserted to indicate that the converter temperature is too high and that the converter is about to shut down. OTW_L will be asserted a minimum of 500 msec before the converter shuts down due to an overtemperature condition. The output of this signal is the open drain of a FET. The output is current limited to 8-15 mA and may be used to drive an external LED directly. (VO – 1.5) VTRIM = —————— + 1.0V 0.30 For the GPH2V2-40 and GPH2V2-60 the output voltage may be trimmed to +15% , - 10%. The trim voltage for these two units is: VTRIM (VO – 2.2) = —————— + 1.0V 0.44 The trim voltage for the GPH3V3-40 and GPH3V3-60 is: (VO – 3.3) VTRIM = —————— + 1.0V 0.66 The trim voltage for the GPH5V0-30 and GPH5V0-40 is: (VO – 5.0) VTRIM = —————— + 1.0V 1.0 Resistor Programming: A resistor may be connected between the Voltage Adjust pin (pin 5) and the – SENSE pin (pin 1) to adjust the output voltage up or down from the nominal output voltage by a maximum of +/- 10 %. The GPH2V2-40, -60 may be adjusted +15 %, -10 %. The value of the trim resistor is for a single converter or for multiple paralleled converters with separate trim resistors on each of their Voltage Adjust pins. Although not recommended, the Voltage Adjust pins for N paralleled converters may be tied together. In this case the value of the trim resistor will be RTRIM/N. For the GPH1V5-40 and GPH1V5-60, the trim resistor value in Kohms for these two units is: (VO – 1.5) RTRIM = —————— + 1.0KΩ 0.30 The resistor value in Kohms for the GPH2V2-40 and GPH2V2-60 is: (VO – 2.2) RTRIM = —————— + 1.0KΩ 0.44 Output Voltage Adjustment: Voltage Programming: A voltage may be applied between the Voltage Adjust pin (pin 5) and the – Sense pin (pin 1) to adjust the output voltage up or down from the nominal output voltage by a maximum of ±10%. Hercules Series, Page 6 The resistor value in Kohms for the GPH3V3-40 and GPH3V3-60 is: (VO – 3.3) RTRIM = —————— + 1.0KΩ 0.66 WWW.GALAXYPWR.COM Part No. 98–002 Rev. 1.1 Application Notes The resistor value in Kohms for the GPH5V0-30 and GPH5V0-40 is: RTRIM 48V L1 2 1 C1 270µF 63V (VO – 5.0) = —————— + 1.0KΩ 1.0 48V RTN Thermal Considerations: Thermal considerations are an important factor in the reliable operation of the converter. The maximum operating baseplate temperature is 100°C. The maximum recommended operating baseplate temperature is 90°C. The baseplate temperature is a function of the losses within the converter, the converter ambient temperature, and airflow across the heat sink. The baseplate temperature can be approximated by the following equation: 1–η TBASEPLATE = POUTPUT*—————*RBASEPLATE-AMBIENT + TAMBIENT η Where: TBASEPLATE is the temperature of the baseplate. TAMBIENT is the local ambient temperature around the converter η is the efficiency of the converter (see table on page 2) RBASEPLATE-AMBIENT is the thermal resistance from the baseplate to the ambient environment. This is a function of the heat sink and air velocity. See table on page 5 for thermal resistance characteristics. Recommended Input Filter, Fuse and Case Connections: A fuse is required in series with the plus or minus side of the 48V input to meet safety requirements. The following input filter circuit is recommended for all applications. The fuse should be inserted between the capacitors and the plus or minus input of the converter. The case should be connected to the output return. 4 80 In (+) UH + C2 1µF 100V ° 3 In (–) + Input – In (–) DC/DC Converter + Output P Enable C3 1µF 100V C4 1µF 100V Case RLOAD – L1 Common Mode Inductor C1 270µF, 63V Aluminum Electrolytic Capacitor C2-C4 1µF, 100V Ceramic capacitor The reference baseplate temperature is measured at the center coordinates of the baseplate. Hercules Series, Page 7 In (+) ° Paralleling Converters: Two to five converters can be paralleled as long as the following conditions are met. When all of the converters are from the same manufacturer the current share pins must be connected together and the sync pins may be connected together if desired. When converters from different manufacturers are paralleled, the current share pins must be connected together and the sync pins must NOT be connected together. The maximum output current for paralleled configurations is shown in the table on page 5. When a converter fails in a parallel configuration it may or may not deassert its MODOK_L signal. It should also be noted that current for the control circuit in the converter flows through the – SENSE lead. For this reason it is important to keep the impedance between the – SENSE pins on the converters in a parallel configuration low. The best approach is to connect the – SENSE pins together with as large of an etch as possible (250 milliohms maximum recommended) and then run a single set of sense leads to the remote sense point at the load. WWW.GALAXYPWR.COM Part No. 98–002 Rev. 1.1 PACKAGE DETAIL Pin Assignments Indicates Pin 1 2.400 Max Power Pins Designation Notes: 1. General Tolerance: .XX = 0.02 .XXX = 0.005 2. Tolerance for 0.040 and 0.080 pins to be 0.002 3. Use 4-40 screws to mount heatsink 4. Bottom surface must be insulated (primary and/or secondary etch may run underneath case) 2.400 Max +Vout –Vout Case N/C –Vin +Vin Signal Pins (25 mils sq.) Pin Designation 1 2 3 4 5 6 7 8 Heatsink Profile 0.555 Max Pin Config. .080 round .080 round .040 round .040 round .040 round .040 round Converter -Sense SYNC MODOK_L OTW_L Voltage Adjust Enable_L Current Share + Sense Recessed M3 Insert, 0.5 inches long (optionsl) 4plcs 0.200 Ref 0.175 0.240 1.900 0.350 –VOUT –VOUT –VOUT 1.250 1.450 0.925 1.750 Case 2.000 N/C –VIN J1 0.300 0.175 4 1 5 8 +VOUT +VOUT +VOUT +VIN 0.700 1.150 1.325 1.500 Galaxy Power Inc. warrants to the original purchaser that the products conform to this data sheet and are free from material and workmanship defects for a period of two (2) years from the date of manufacture, if this product is used within specified conditions. Galaxy Power Inc. reserves the right to make changes to the product(s) or information contained herein without notice. No liability is assumed as a result of their use or application. No rights under any patent accompany the sale of any such products or information. For additional details on this limited warranty consult the factory. 0.100 Bottom View (facing pins) ORDERING INFORMATION Model Number GPH5V0-40 GPH5V0-30 GPH3V3-50 GPH3V3-40 Output Voltage Max Current Efficiency (Typ) 5.0V 5.0V 3.3V 3.3V 40 A 30 A 50 A 40 A 85% 86% 81% 82% Model Number GPH2V2-60 GPH2V2-40 GPH1V5-60 GPH1V5-40 Output Voltage Max Current Efficiency (Typ) 2.2V 2.2V 1.5V 1.5V 60 A 40 A 60 A 40 A 74% 75% 67% 68% * Heatsinks required: available on request. See table on page 5. 155 Flanders Road Westborough, MA 01581 508–870–9775 Fax: 508–870–9796 e–mail: [email protected] website: http://www.galaxypwr.com © Copyright 2000 Galaxy Power. Specifications subject to change without notice. Hercules Series, Page 8 WWW.GALAXYPWR.COM Part No. 98–002 Rev. 1.1